Reinforced impact beam with layered matrix

Abstract

An impact beam having a polymer matrix and a metal reinforcing structure, the metal reinforcing structure including metal cords that can be made from metal elements having a diameter of 100 μm or more. The polymer matrix can include a thermoplastic material and/or a fiber material, and the metal can be steel, and the metal cords can be parallel to each other. The polymer matrix can include two or more layers that can be made from the same or different material, one of which can be positioned around the surface of the metal cords and can have a mechanical bond with the cord. The invention also includes a method of making the impact beam.

1 . A method for providing an impact beam, comprising the steps of: 
 providing a polymer matrix sheet;    providing metal cords and/or metal cord tapes comprising metal cords;    heating the polymer matrix sheet;    bringing the metal cords and/or metal cord tapes and polymer matrix sheet together and providing the metal cords and/or metal cord tapes and polymer matrix sheet to a mold;    molding the metal cords and/or metal cord tapes and polymer matrix sheet to thereby provide an impact beam for impact reinforcement; and    causing and/or allowing the impact beam to cool.    
   
   
       2 . The method of  claim 1 , wherein the polymer matrix sheet comprises glass fibers.  
   
   
       3 . A method for providing an impact beam, comprising the steps of: 
 providing metal cords and/or metal cord tapes comprising metal cords;    extruding polymer material and providing extruded polymer material to the metal cords and/or metal cord tapes;    molding the metal cords and/or metal cord tapes and polymer material to thereby provide an impact beam for impact reinforcement; and    causing and/or allowing the impact beam to cool.    
   
   
       4 . A method for providing an impact beam, comprising the steps of: 
 providing fiber strands and/or reinforcing fabrics;    providing metal cords and/or metal cord tapes comprising metal cords;    providing uncured or not fully cured polymer material to the fiber strands and/or the reinforcing fabrics and the metal cords and/or metal cord tapes by drawing the fiber strands and/or the reinforcing fabrics and the metal cords and/or metal cord tapes through a bath of uncured or not fully cured polymer material;    curing the fiber strands and/or the reinforcing fabrics and the metal cords and/or metal cord tapes and the uncured or not fully cured polymer material by drawing the fiber strands and/or the reinforcing fabrics and the metal cords and/or metal cord tapes and the uncured or not fully cured polymer material through a heated pultrusion die to thereby provide a pultruded article; and    cutting the pultruded article to lengths to thereby provide an impact beam for impact reinforcement.    
   
   
       5 . A method of providing an impact beam, comprising the steps of: 
 providing metal cords and/or metal cord tapes comprising metal cords;    bringing the metal cords and/or metal cord tapes in an extrusion mold and positioning the metal cords and/or metal cord tapes in the mold;    providing polymer material in the extrusion mold to provide an impact beam for impact reinforcement; and    causing and/or allowing the impact beam to cool.    
   
   
       6 . The method of  claim 5 , further comprising the steps of providing glass fibers and positioning the glass fibers in the extrusion mold.  
   
   
       7 . The method of  claim 3 , wherein the polymer material includes glass fibers.  
   
   
       8 . The method of  claim 1 , wherein the metal cord tapes comprise metal cords and a polymer matrix around the metal cords.  
   
   
       9 . The method of  claim 3 , wherein the metal cord tapes comprise metal cords and a polymer matrix around the metal cords.  
   
   
       10 . The method of  claim 4 , wherein the metal cord tapes comprise metal cords and a polymer matrix around the metal cords.  
   
   
       11 . The method of  claim 5 , wherein the metal cord tapes comprise metal cords and a polymer matrix around the metal cords.  
   
   
       12 . The method of  claim 1 , further comprising the step of heating the metal cords and/or metal cords tapes.  
   
   
       13 . Use of the impact beam of  claim 1  for support of bumpers of vehicles and/or to improve impact resistance of a vehicle's coachwork.  
   
   
       14 . Use of the impact beam of  claim 3  for support of bumpers of vehicles and/or to improve impact resistance of a vehicle's coachwork.  
   
   
       15 . Use of the impact beam of  claim 4  for support of bumpers of vehicles and/or to improve impact resistance of a vehicle's coachwork.  
   
   
       16 . Use of the impact beam of  claim 5  for support of bumpers of vehicles and/or to improve impact resistance of a vehicle's coachwork